Blank and an open-top carton constructed therefrom

ABSTRACT

A container comprises a bottom ball, opposite pair of end walls, and opposite pair of side walls. The opposite pair of the end walls foldably joined to opposite ends of the bottom wall and the opposite pair of side walls foldably joined to opposite sides of the bottom wall. The pair of side walls and the pair of end walls cooperating with one another to form an open-top tray. Each of the pair of side walls comprising at least one locking tab integrally formed on at least one end of the respective pair of side walls to securely lock the pair of side walls and the pair of end walls to one another.

BACKGROUND OF THE INVENTION

The present invention relates generally to paperboard cartons and moreparticularly, to a die cut blank and an open-top carton tray assembledtherefrom.

Conventional foldable cartons are well known and are used in a varietyof applications. For example, the packaging industry utilizes a vastnumber of cartons in which numerous products are packaged for subsequentshipment. Current frame-vue tray cartons used for packaging golf ballrequire forming machinery that has expensive tooling that must bechanged for each size package. Also, the short side walls ofconventional packages can be pushed into the frame by the weight of thegolf balls, resulting in creases and tears to the package.

SUMMARY OF THE INVENTION

The present invention relates to a package comprising an open-top tray,a plurality of sleeve boxes, and a cover to fit over the open-top cartontray to thereby enclosing the sleeve boxes therein for shipping, storingand sale.

Accordingly, one aspect of the present invention relates to a containercomprises a bottom ball, opposite pair of end walls, and opposite pairof side walls. The opposite pair of the end walls are foldably joined toopposite ends of the bottom wall and the opposite pair of side walls arefoldably joined to opposite sides of the bottom wall. The pair of sidewalls and the pair of end walls are cooperating with one another to forman open-top tray. Each of the pair of side walls comprises at least onelocking tab that is integrally formed on at least one end of therespective pair of side walls to securely lock the pair of side wallsand the pair of end walls to one another.

Another aspect of the present invention relates to a paperboard blankfor making a container having a bottom wall, opposite end walls, andopposite side walls. A central panel comprises opposite side edges andopposite end edges, and which forms the bottom wall of the container. Aside panel is foldably joined to each of the side edges of the centralpanel. An end panel is foldably joined to each of the end edges of thecentral panel. The side panels and the end panels are configured to formrespective side walls and end walls in a container made from the blank.Each of the side walls comprises at least one locking tab that isintegrally formed on at least one end of the respective pair of sidewalls to securely lock the pair of side walls and the pair of end wallsto one another.

A further aspect of the present invention relates to a containercomprising a bottom ball, opposite end walls being defined by inner andouter end walls, and opposite side walls being defined by inner andouter side walls. The end walls are foldably joined to opposite ends ofthe bottom wall and the side walls are foldably joined to opposite sidesof the bottom wall. The side walls and the end walls are cooperatingwith one another to form an open-top tray. Each of the side walls havingat least one locking tab is integrally formed on at least one end of therespective pair of side walls to securely lock the pair of side wallsand the pair of end walls to one another. At least one locking tabinhibits deflection of the inner end wall relative to the outer endwall.

BRIEF DESCRIPTION OF THE DRAWINGS

A full understanding of the invention can be gained from the followingdescription of the preferred embodiments when read in conjunction withthe accompanying drawings in which:

FIG. 1 is an exploded perspective view of a package including a cover,an open-top carton tray and a plurality of sleeve boxes positionablewithin the open-top carton tray in accordance to a preferred embodimentof the present invention;

FIG. 2 is a top view of a blank used to construct the open-top cartontray of FIG. 1;

FIG. 3 is a close-up view of a portion of a side wall of the open-topcarton tray shown in FIG. 2;

FIG. 4 is a close-up view of a portion of an end wall of the open-topcarton tray shown in FIG. 2;

FIGS. 5A-5D illustrate the steps in constructing the open-top cartontray from the blank in FIG. 2 in accordance with the preferredembodiment of the present invention.

DETAIL DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows a package 10 in accordance with one embodiment of thepresent invention, wherein the package 10 comprises an open-top cartontray 12 and a plurality of sleeve boxes 14 configured to be positionedwithin the open-top carton tray 12. A cover 16 may be used to fit overthe open-top carton tray 12, thereby enclosing the sleeve boxes 14therein for transporting the package 10.

The cover 16 includes a top panel 11 having a pair of side panels 13a,13 b and a pair of end panels 15 a, 15 b extending from the top panel11 at generally right angles to form an interior space 17. The sidepanels 13 a, 13 b and the end panels 15 a, 15 b may have equal heightswith one another and in turn, correspond to the height of the open-topcarton tray 12.

The open-top carton tray 12 includes an interior space 18, into whichthe plurality of sleeve boxes 14 may be positioned. Each of theplurality of sleeve boxes 14 contains a number of golf balls (not shown)or other items, although any item may be used in connection with thepackage 10 according to the present invention without departing from thescope of the invention. For example, FIG. 1 illustrates five sleeveboxes 14 configured to be placed within the interior space 18 of theopen-top carton tray 12, but depending on the size and shape of theopen-top carton tray 12, any number of sleeve boxes 14 may be disposedin the interior space 18 and that the sleeve boxes 14 do not move aboutwithin the interior space 18 during shipping. The plurality of sleeveboxes 14 are sized and shaped such that a maximum number of these sleeveboxes 14 can be placed in the interior space 18. As an example shown inFIG. 1, the plurality of sleeve boxes 14 are rectangular in shape, butother shapes may be used as well. The package 10 is generallyrectangular in shape; however, other geometrical shapes may be usedaccordingly.

The open-top carton tray 12 is preferably constructed from a flat sheetof heat-resistant laminated linerboard or corrugated paperboard having alaminated linerboard, although any foldable material may be used. Theopen-top carton tray 12 is formed from a blank 20 (shown in FIG. 2)which is scored and cut to define a series of foldably interconnectedwalls and panels as hereinafter described. It is well within the scopeof this invention to use any suitable material well known or laterdeveloped in the art such as, for example, plastic, foil or the like.

FIG. 2 is a top view of the blank 20 used to construct the open-topcarton tray 12. The blank 20 is divided into three major sections by twosubstantially parallel longitudinal fold lines 22, 24 and furtherdivided into three minor segments by two substantially paralleltransverse fold lines 26, 28. Bottom panel 30 is formed by theintersection of the respective two transverse fold lines 26, 28 andrespective longitudinal fold lines 22, 24. End panels 32 a, 32 b areformed by respective transverse fold lines 26, 28 and are generallyopposite-hand to one another along an imaginary transverse centerline(not shown) at the bottom panel 30.

When the blank 20 is formed into the open-top carton tray 12 as shown inFIG. 1, each of the end panel 32 a, 32 b is formed into respective endwalls 34 a, 34 b and 34 c, 34 d, and respective landing surface 36 a, 36b. The end walls 34 a, 34 b are spaced apart from one another by thelanding surface 36 a and the end walls 34 c, 34 d are spaced apart fromone another by the landing surface 36 b. The landing surface 36 a isformed by two parallel fold lines 38 a, 40 a and the landing surface 36b is formed by two parallel fold lines 38 b, 40 b. The end walls 34 a,34 c define outer walls and the end walls 34 b and 34 d define innerwalls. Slots 35 a, 35 b, 35 c, 35 d are formed into the respectivelanding surfaces 36 a, 36 b and the respective inner walls 34 b, 34 d.For example, and only for illustrative purpose, FIG. 4 depicts thedetail of the slot 35 a with respect to inner end wall 34 b and landingsurface 36 a. The detail of other slots 35 b, 35 c, and 35 d areidentical to that of FIG. 4 and as such, a detailed View of each of theslots 35 b, 35 c, and 35 d will be omitted to avoid redundancy. Each ofthe respective end panels 32 a, 32 b includes a respective glue flap 42a, 42 b that is defined by respective creased lines 44 a, 44 b. The glueflaps 42 a, 42 b project outwardly from the walls 34 b, 34 d and each isprovided with a quantity of adhesive thereon for properly securing theidentical end panels 32 a, 32 b to the bottom wall 30. Alternative formsof securing end panels 32 a, 32 b to the bottom wall 30 may be used suchas by staple, slots and tabs, etc.

Similarly, side panels 46 a, 46 b are formed by fold lines 22, 24,respectively. When the blank 20 is formed into the open-top carton trayas shown in FIG. 1, the side panel 46 a is formed into walls 48 a, 48 band the side panel 46 b is formed into walls 48 c, 48 d. The walls 48 a,48 b are spaced apart by a landing surface 50 a and the walls 48 c, 48 dare spaced apart by a landing surface 50 b. The walls 48 a, 48 c definerespective outer walls and the walls 48 b, 48 d define respective innerwalls. Each of the identical side panels 46 a, 46 b includes arespective glue flap 47 a, 47 b that are defined by respective creasedlines 49 a, 49 b. Each glue flap 47 a, 47 b projects outwardly from itsrespective walls 48 b, 48 d and each glue flap 47 a, 47 b is providedwith a quantity of adhesive thereon for properly securing the respectiveside panel 46 a, 46 b to the bottom wall 30. Alternative forms ofsecuring side panel 46 a, 46 b to the bottom wall 30 may be used such asby staple, slots and tabs, etc.

The walls 48 a, 48 c are spaced apart from one another by the landingsurface 50 a and the walls 48 b, 58 d are spaced apart from one anotherby the landing surface 50 b. The landing surface 50 a is defined by twoparallel fold lines 52 a, 54 a and the landing surface 50 b is definedby two parallel fold lines 52 b, 54 b.

Each of the respective side panels 42 a, 42 b includes two pair ofrespective locking tabs 56 a, 56 b, 56 c, and 56 d that extend fromrespective ends of the landing surfaces 50 a, 50 b. Although the presentinvention discloses a pair of locking tabs 56 a, 56 b on the side panel42 a and a pair of locking tabs 56 d 56 c on the side panel 42 b, onlyone locking tab on each side panels 42 a, 42 b (depending on the design)may be used. The locking tabs 56 a, 56 b extend from the opposed ends ofthe fold line 52 a and the locking tabs 56 c, 56 d extend from opposedends of the fold line 52 c. In addition, the locking tabs 56 a, 56 b and56 c, 56 d are formed and die cut into the respective side panels 46 a,46 b and are substantially similar with one another. The respectivelocking tabs 56 a, 56 b form respective cut outs 58 a, 58 b andrespective slots 60 a, 60 b with the inner side wall 48 b. Similarly,the respective locking tabs 56 c, 56 d each form respective cut outs 58c, 58 d and respective slots 60 c, 60 d with the inner side wall 48 d.

For illustrative purpose, FIG. 3 depicts the details of cut out 58 a andslot 60 a with respect to the inner side wall 48 b. When the blank 20 isfolded to form the open-top tray 12 as depicted in FIG. 1, therespective slots 60 a, 60 b and 60 c, 60 d on the respective side panels46 a, 46 b are intimately engaged with the corresponding slots 35 a, 35b and 35 c, 35 d on the end panels 32 a, 32 b and the locking tabs 56 a,56 b and 56 c, 56 d are concealed under the respective landing surface36 a, 36 b. Each of the locking tabs 56 a, 56 b and 56 c, 56 d providesadditional support to the inner walls 34 b, 34 c by securely holding theinner walls 34 b, 34 c of the end panel 32 a, 32 b in the verticalposition and preventing the inner walls 34 b, 34 c from deflectingoutwardly from the bottom wall 30.

For illustrative purpose, FIG. 5D depicts a partially cut out view oftwo corners of the open-top tray 12. The other two corner of theopen-top tray 12 are exactly the same and the locking tabs 56 b and 56 care concealed each corner of the tray 12. Each of the locking tabs 56 a,56 b, 56 c, and 56 d has a length (L) that permits maximum support forthe inner walls 34 b, 34 d when the locking tabs 56 a, 56 b and 56 c, 56d are in locking positions. As the free body diagram illustrates, thereare generally three major forces, namely, glue force F_(g), tear forceF_(t), and locking tab force F_(l). The glue force F_(g) acts downwardlyto hold in place the end panel 32 b (as shown in FIG. 2) and in turn,the inner wall 34 d, to the bottom wall 30. The locking tab force F_(l)acts as an I-beam structure to stiffen the inner wall 34 d in thevertical position. The tear force F_(t) is caused by the sleeve boxes 14which act against the end panel 32 b in vertical position, to tear theinner wall 34 d from the bottom wall 30 when the sleeve boxes 14 aretightly fit inside the open-top carton tray 12. Each of the locking tabs56 a, 56 b and 56 c, 56 d lies in a plane that is substantiallyperpendicular to a vertical plane in which the outer wall 34 c lies andalso substantially perpendicular to a vertical plane in which the innerwall 34 d lies. As such, each of the locking tabs 56 a, 56 b and 56 c,56 d provides an I-beam-like structure wherein the tab 56 d functionslike a web portion of an I-beam to stiffen the inner wall 34 d, therebyinhibiting deflection of the inner wall 34 d relative to the outer wall34 c. This is particularly important in a certain region of the innerwall 34 d, where deflection of the inner wall 34 d is not resisted byeither the landing surface 36 b of the outer wall 34 c or by the flap 42b, which is glued directly to the bottom wall 30. It should be notedthat the magnitude of two locking tab force F_(l) plus the glue forceF_(g) is much greater than the magnitude of the tear force F_(t) andthus the present invention produces a sturdy open-top carton tray 12.The locking tabs 56 a, 56 b and 56 c, 56 d of the present invention areexemplary and thus, other design of the locking tabs with variouslengths and shapes may be used as well.

FIGS. 5A-5D illustrate the steps of constructing the blank 20 to formthe open-top carton tray 12 as described hereinabove with respect toFIG. 2. Manual set-up of the open-top carton tray 12 is easilyaccomplished. First, as shown in FIG. 5A, the respective side panels 46a, 46 b and end panels 32 a, 32 b are folded inwardly or toward thebottom wall 30 (as shown in FIG. 2) at the respective fold lines 52 a,52 c and 40 a, 40 b and the respective flaps 47 a, 47 b and 42 a, 42 bare preferably glued to inside of the bottom wall 30. Depending on thealternative design, the flaps 42 a, 42 b may be tucked or stapled orslided into a jacket within the bottom wall 30.

Next, in FIG. 5B, the end walls 34 a, 34 b, 34 c, 34 d are folded atsubstantially 90 degrees with respect to the bottom wall 30. While in anupright position, the end walls 34 a, 34 b, 34 c, 34 d are substantiallyparallel with one another.

Referring now to FIG. 5C, one side panel 46 a is folded inwardly atsubstantially 90 degrees with respect to the bottom wall 30 at the foldlines 22 and the other side panel 46 b is folded inwardly atsubstantially 90 degrees with respect to the bottom wall 30 at the foldlines 24. In an upright position, the side walls 48 a, 48 b and 48 c, 48d are substantially parallel with one another and the locking tabs 56 a,56 b and 56 c, 56 d and the corresponding slots 60 a, 60 b and 60 c, 60d are intimately engaged with the end walls 34 a, 34 b, 34 c, and 34 das best depicted in FIG. 5D. The locking tabs 56 a, 56 b and 56 c, 56 dare concealed under their respective landing surface 36 a, 36 b.Finally, the plurality of sleeve boxes 14 are tightly placed in theinterior space 18 in a manner that the length of the each sleeve box 14corresponds to the width of the open-top tray 12.

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted withoutdeparting from the scope of the invention. In addition, manymodifications may be made to adapt a particular situation or material tothe teachings of the invention without departing from its scope.Therefore, it is intended that the invention not be limited to theparticular embodiment disclosed, but that the invention will include allembodiments falling within the scope of the appended claims.

1. A container comprising a bottom ball, opposite pair of end walls, andopposite pair of side walls, the opposite pair of the end walls foldablyjoined to opposite ends of the bottom wall and the opposite pair of sidewalls foldably joined to opposite sides of the bottom wall, the pair ofside walls and the pair of end walls cooperating with one another toform an open-top tray and wherein each of the pair of side wallscomprising at least one locking tab integrally formed on at least oneend of the respective pair of side walls to securely lock the pair ofside walls and the pair of end walls to one another.
 2. The container ofclaim 1 wherein each of the side walls comprises two locking tabsintegrally formed on opposed ends of the each side walls.
 3. Thecontainer of claim 1 wherein each of the locking tabs is die cut intothe side walls by forming a cut out and a slot therein.
 4. The containerof claim 1 wherein the at least one locking tab support the pair of theside walls when the at least one locking tab is in a locking position.5. The container of claim 4 wherein the locking position is defined byfrictionally engaging the at least one locking tab with a slot formedbetween inner and outer end wall panels.
 6. The container of claim 1wherein each of the locking tab functions like a web portion of anI-beam to stiffen the pair of the side walls.
 7. The container of claim1 wherein the side walls are defined by inner and outer wall panels andwherein the locking tab inhibits deflection of the inner wall panelrelative to the outer wall panel.
 8. The container of claim 1 whereinthe side wall panels are spaced apart by a landing surface.
 9. Thecontainer of claim 8 wherein the landing surface is defined by twoparallel fold lines.
 10. The container of claim 1 further comprising aplurality of sleeve boxes positioned within the open-top tray.
 11. Thecontainer of claim 1 further comprising a cover fit over the open-toptray.
 12. A paperboard blank for making a container having a bottomwall, opposite end walls, and opposite side walls, comprising: a centralpanel having opposite side edges and opposite end edges, and which formsthe bottom wall of the container; a side panel foldably joined to eachof the side edges of the central panel; an end panel foldably joined toeach of the end edges of the central panel, the side panels and the endpanels configured to form respective side walls and end walls in acontainer made from the blank and wherein each of the side wallscomprising at least one locking tab integrally formed on at least oneend of the respective pair of side walls to securely lock the pair ofside walls and the pair of end walls to one another.
 13. The paperboardblank of claim 12 wherein the side walls are defined by inner and outerwall panels wherein the inner and outer wall panels are positioned atsubstantially right angle with respect to the bottom wall.
 14. Thepaperboard blank of claim 12 wherein the inner and outer wall panels arespaced apart from one another by a landing surface.
 15. The paperboardblank of claim 13 wherein the landing surface is formed by a pair ofparallel fold lines.
 16. The paperboard blank of claim 12 each of thelocking tabs is die cut into the side panels by forming a cut out and aslot therein.
 17. A container comprising a bottom ball, opposite endwalls being defined by inner and outer end walls, and opposite sidewalls being defined by inner and outer sides walls; the end wallsfoldably joined to opposite ends of the bottom wall and the side wallsfoldably joined to opposite sides of the bottom wall, the side walls andthe end walls cooperating with one another to form an open-top tray,each of the side walls having at least one locking tab integrally formedon at least one end of the respective pair of side walls to securelylock the pair of side walls and the pair of end walls to one another andwherein the at least one locking tab inhibits deflection of the innerend wall relative to the outer end wall.
 18. The container of claim 17wherein the at least one locking tab lies in a plane that issubstantially perpendicular to a vertical plane in which the outer endwall panel lies and wherein the at least one locking tab substantiallyperpendicular to a vertical plane in which the inner end wall panellies.